System and method for manufacturing composite materials having substantially uniform properties

Abstract

A system and method for manufacturing composite material components having substantially uniform properties comprising means to control the metering of constituent composite material components during manufacture. The resulting composite material components may, for example, be used in the construction of decking systems, railing, porches, fences, stairs, or other similar or suitable applications that may benefit from aesthetically pleasing appearances.

Description

BACKGROUND AND SUMMARY OF THE INVENTION[0001]Exemplary embodiments of the present invention relate generally to composite products. More particularly, exemplary embodiments of the present invention include systems and methods directed to the control of manufacturing processes used to manufacture composite materials such as cellulosic-filled and / or inorganic-filled plastic composites. Such composite materials have a wide range of application and may, for example, be used in the manufacture of gates, fences, porch and deck skirts, and other similar or suitable structures.[0002]A major problem with the use of wood materials in structural applications is their lack of durability and the degradation in appearance when exposed to the environment. Wood materials are particularly attractive due to their intrinsic beauty of their wood grain. However, in the example of residential decks, rain can infiltrate exposed surfaces of the wood components, which may eventually cause rot and the loss o...

AI Technical Summary

Benefits of technology

[0002]A major problem with the use of wood materials in structural applications is their lack of durability and the degradation in appearance when exposed to the environment. Wood materials are particularly attractive due to their intrinsic beauty of their wood grain. However, in the example of residential decks, rain can infiltrate exposed surfaces of the wood components, which may eventually cause rot and the loss of a pleasing aesthetic appearance. Traditional wood surface treatments, such as paint or lacquers, have limited life and require routine maintenance, which can result in significant expense over time. Additionally, wood decking systems, for example, are typically custom-built on-site, thereby requiring significant amounts of labor to custom-cut and install individual components. More recently, pre-engineered cellulosic-filled and / or inorganic-filled plastic composites have been developed to overcome such deficiencies. As compared to natural woods, a cellulosic composite may offer superior resistance to wear and tear and to degradation caused by adverse weathering effects, which reduces overall maintenance costs. For instance, a cellulosic composite may have an enhanced resistance to moisture. In fact, it is well known that the retention of moisture is a primary cause of the warping, splintering, and discoloration of natural woods as described above. Moreover, a cellulosic composite may be sawed, sanded, shaped, turned, fastened, and finished in a similar manner as natural woods.

Problems solved by technology

A major problem with the use of wood materials in structural applications is their lack of durability and the degradation in appearance when exposed to the environment.

However, in the example of residential decks, rain can infiltrate exposed surfaces of the wood components, which may eventually cause rot and the loss of a pleasing aesthetic appearance.

Traditional wood surface treatments, such as paint or lacquers, have limited life and require routine maintenance, which can result in significant expense over time.

Additionally, wood decking systems, for example, are typically custom-built on-site, thereby requiring significant amounts of labor to custom-cut and install individual components.

In fact, it is well known that the retention of moisture is a primary cause of the warping, splintering, and discoloration of natural woods as described above.

However, since the production of extruded composite materials is generally a continuous process, undesirable density variation in the final product occurs because density variations of the introduced base components occur over relatively short time periods.

In particular, the components cannot be adequately metered real-time for compensation of variations during mixing by manual operator control.

For similar reasons, the control of color is difficult as the amounts of colorants cannot be satisfactorily controlled real-time, producing undesirable variation in color in the final product.

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